Mass repeatable thermoformable sheet such as which may be applied over a scrim material to produce a decorative and structural article

Abstract

A structurally applicable and thermofoil incorporating article including a body having a substantially thin and planar configuration with a height, width and thickness and with a protective upper layer overlaying at least one interior layer including the thermofoil material. Colorants and additives including veining patterns and stone, glass or metal effecting granules serve to provide additional desired visual effects to the article, and which is capable of being extruded, roll or sheet formed and shipped in bulk. The article is further capable of being applied in a semi-fluidic state upon an uneven, typically male blank or scrim, and so as to anneal thereto without excessive stress accumulations.

1 . A thermoformable sheet capable of being applied to a three-dimensional and substantially planar shaped article, comprising:
 said sheet having a specified thickness and including at least one layer exhibiting a decoratively effecting material; and   said sheet further exhibiting a thickness no greater than 10% of a least planar dimension associated with the article about which said sheet is secured.   
   
   
       2 . The thermoformable sheet as described in  claim 1 , said sheet having a specified shape and size and further comprising a polyolefin resin. 
   
   
       3 . The thermoformable sheet as described in  claim 1 , said sheet exhibiting a thickness in a range of between 0.008″ to 0.050″. 
   
   
       4 . The thermoformable sheet as described in  claim 2 , further comprising at least one rearward layer applied to said sheet and comprising a thickness in a range of 0.001″ to 0.030″. 
   
   
       5 . The thermoformable sheet as described in  claim 4 , an uppermost layer associated with said sheet exhibiting a specified degree of visibility, ranging from substantially clear to partially translucent, and further comprising at least one type of said decoratively effecting material. 
   
   
       6 . The thermoformable sheet as described in  claim 4 , further comprising at least one decoratively effecting interior layer exhibiting a colored stratum for imparting said decorative effect through a top layer. 
   
   
       7 . The thermoformable sheet as described in  claim 6 , further comprising a plurality of granules entrained within at least one of said upper and interior layers, said granules each having a specified size and being selected from a group exhibiting at least one of metallic, stone and silicate/glass effects. 
   
   
       8 . The thermoformable sheet as described in  claim 7 , the article exhibiting at least one non-planar arcuate extending edge, at least a portion, by weight, of said granules exhibiting a degree of bendability/fragmentation at a region proximate the non-planar edge. 
   
   
       9 . The thermoformable sheet as described in  claim 7 , said decorative granules having a specified shape and size exhibiting a sufficient modulus of elasticity to permit substantially non-segmenting bending during formation of said non-planar edge. 
   
   
       10 . The thermoformable sheet as described in  claim 4 , said upper layer having a specified shape and size and further comprising at least one material selected from a group including a polypropylene and a polyethylene material, said rearward layer further being selected from a least one of an ABS, acrylic and an EVA material. 
   
   
       11 . The thermoformable sheet as described in  claim 3 , exhibiting a specified degree of elasticity and capable of being fabricated in at least one of a rigid stackable sheet and a winded sheet roll for distribution. 
   
   
       12 . The thermoformable sheet as described in  claim 4 , said protective upper layer further comprising at least one of a non-porous acrylic, a polyester and a polyolefin material. 
   
   
       13 . The thermoformable sheet as described in  claim 6 , further comprising said interior layer contributing a degree of structural thickness and opacity such that light transmission is blocked from an angle of 180° relative to a viewable surface of said interior layer. 
   
   
       14 . The thermoformable sheet as described in  claim 4 , said upper layer further comprising a non-dispersing color additive for creating a veined pattern. 
   
   
       15 . The thermoformable sheet as described in  claim 4 , said upper layer further comprising a decorative and index-of-refraction-matching crushed mineral selected from at least one of a silaceous, a calcined, and an oxidized metal material. 
   
   
       16 . The thermoformable sheet as described in  claim 15 , each of said minerals being aqueous based and exhibiting an average mean diameter of less than 3,000 nm. 
   
   
       17 . The thermoformable sheet as described in  claim 15 , said mineral material being entrained into the decorative layer at about 10-40% by weight, in cooperation with additional decorative effect materials including at least one of UV stabilizers, epoxoid binders and stress reliever. 
   
   
       18 . A thermoformable sheet capable of being applied to a three-dimensional and substantially planar shaped article, comprising:
 said sheet having a specified thickness and including at least one layer exhibiting at least one filler material exhibiting a sufficiently high thermal conductivity to facilitate heat transfer during at least one of forming and curing processes associated with formation of said sheet; and   said sheet further exhibiting a thickness no greater than 10% of a least planar dimension associated with the article about which said sheet is secured.   
   
   
       19 . The thermoformable sheet as described in  claim 18 , said filler material further comprising a polypropylene resin exhibiting a coefficient of linear thermal expansion of 9.0×10 −5  mm/mm/° C. 
   
   
       20 . The thermoformable sheet as described in  claim 18 , further comprising a polyolefin material layer entrained with a mineral and exhibiting a coefficient of linear thermal expansion of less than 9×10 −5  mm/mm/° C. 
   
   
       21 . The thermoformable sheet as described in  claim 20 , further comprising said polyolefin material layer having a selected length, width and thickness with a polymer orientation in both linear and crosswise directions of less than 50%. 
   
   
       22 . The thermoformable sheet as described in  claim 20 , further comprising at least one thermally conductive additive incorporated into said polyolefin material, such mineral featuring a thermal conductivity greater than 0.35. 
   
   
       23 . A polymer sheet comprising:
 a translucent polymeric matrix formed into said sheet and defining an outer face and a backing surface, said sheet further exhibiting a thickness no greater than 10% of a least planar dimension associated with an article about which said sheet is secured;   said sheet comprising at least one visible and decorative granule component larger than 0.004″ and smaller than 0.6″ in planar size, said granules being present across at least 10% of a total visible surface area of said sheet;   a further decorative component being incorporated within said sheet and selected from at least one of a pigment, a dye, and a dispersion dye;   wherein said first decorative component varies from said second decorative component.   
   
   
       24 . The polymer sheet as described in  claim 23 , said sheet having a specified shape and size and further comprising said granules distributed across more than one individual strata layer associated with a multi-layer structure. 
   
   
       25 . The polymer sheet as described in  claim 24 , said sheet having a specified shape and size and further comprising at least three layers incorporating individual pluralities of said granules collectively visible across at least 20% of a total planar surface area of said sheet. 
   
   
       26 . The polymer sheet of  claim 23 , wherein said decorative granular component includes at least one of a cleaved mineral particulate, a shredded plastic film, and a biopolymer particulate. 
   
   
       27 . The polymer sheet as described in  claim 23 , wherein said further decorative component is embedded within said decorative granular component. 
   
   
       28 . The polymer sheet as described in  claim 23 , wherein said polymeric matrix has a thickness of between 0.01 and 0.10 inches. 
   
   
       29 . The polymer sheet as described in claim sheet of  claim 24 , further comprising a granular coating applied intermediate between said polymeric matrix and a first selected granular entrained strata layer. 
   
   
       30 . The polymer sheet as described in  claim 23 , further comprising a back zone secured to a backing surface associated with said matrix. 
   
   
       31 . The polymer sheet as described in  claim 30 , further comprising an adhesive secured intermediate between said back zone and the article about which the sheet is secured. 
   
   
       32 . The polymer sheet as described in  claim 31 , wherein said adhesive is transparent. 
   
   
       33 . The polymer sheet as described in  claim 23 , further comprising a surface protective layer applied to said viewable surface area of said sheet.